Formula SAE Suspension

Engineering Design Specification EML 4501C/ EAS 4700C Group #11

Team Redline
Chevy Butman Gregory Benjamin Phillip Blitz Emmanuel Garcia Nicholas Schiavone Dr. Lionel Hewavitharana EGN1-217 3/2/2012
Introduction Design problem description Intended / unintended uses Special Features Customer Requirements Functional Performance Operating Environment Human Factors Economic Safety Appearance Reliability Robustness Maintenance Pollution Repair Retirement Company Requirements Marketing Manufacturing Financial Regulations/Standards/Codes Patents / intellectual property Other Appendices

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Introduction We are designing a suspension system for University of Central Floridas chapter of SAE. Its intended use is for a formula car that is to be entered into the international Formula SAE competition in May 2013. It will be critiqued by judges at this competition as well as the rest of the car, and will also be used in a 30 minute endurance race, as well as during testing. The intended features of this suspension will be focused on racing performance, and allowing the car to have the fastest possible lap times. Customer Requirements Functional Performance The suspension systems function is to control the motion of the vehicles mass using springs and dampers. The system is designed for performance, with the express purpose of carrying as much speed as possible through corners without upsetting the cars balance. The suspension system is designed in conjunction with the tire setup to prevent understeer as well as oversteer through the corners on the track, as well as to provide the driver of the vehicle with feedback on the cars traction. Operating Environment The operating conditions for a suspension system would vary greatly depending on the particular event. For the SAE competition, the suspension must perform well in a climate common to Michigan in the early summer. This means that components must be engineered to perform in a warm climate with the possibility of precipitation. Since the rulebook for SAE Formula states that the competition would be held in dry, damp or wet conditions. The reduced traction, or grip, resulting from rain will be a factor in designing the suspension. The rules also dictate a tire choice for each of the possible conditions, the effects of which will be considered during the design of the suspension. Other than rain, the climate will be within a window where most material properties are not affected significantly. Human Factors Different drivers drive better with different tires. How we design the suspension can be tailored for an experienced driver or an inexperienced driver, given how fast the tires react to a given input.During testing, we will get feedback from our data acquisition and the driver. At that point we should be able to tune the car accordingly. Economic With regard to the cost and profitability of a functional suspension system, there will be a compromise between price, strength, and weight. The team will optimize components to be sure that materials and manufacturing are within a prescribed budget. For the purpose of the SAE Formula event, the team will utilize parts acquired from sponsorships as well. Special care is to be taken for complicated designs to be sure that they can be easily manufactured, and not requiring special tools or processes that would increase the cost. Ultimately, the suspension components should be cost effective to manufacture and repair, should it be necessary. Geometric Limitations

The wheelbase cannot be less than 60 inches long and the track cannot be less than 75% of the track. Safety The suspension will be tested for its strength under the loads experienced in driving, and designed with an appropriate factor of safety. This is to ensure that a suspension failure is unlikely to occur during the race, which could be potentially dangerous. Appearance Since the SAE Formula event involves a static competition where judges view the suspension of the car, the appearance plays a minor role in scoring. For the sake of competition points, all manufacturing should present uniform and quality workmanship. Each part should be purpose built and should aesthetically reflect a high level of quality. Reliability Reliability is a major factor in the Formula SAE Suspension. Part of the competition is an endurance race, which accounts for nearly 40% of the score. If anything breaks or the car stops running, youre out of the event. Not only do we have to worry about the endurance event, but we are also dealing with something that will be holding another human being, and any accidents will be unacceptable. Robustness The suspension design will accommodate for wheel travel, ground clearance and stability during maximum performance. Suspension must be equipped with shock absorbers, front and rear, with visible mounting points. The suspension will allow and not hinder the driver from operating the vehicle to its maximum engine power output. As a result of the implementation of a properly design suspension, the vehicle will demonstrate optimal handling in competition and in the autocross circuit. Maintenance The suspension system will be visible to any technicians who need to repair it, and designed with simplicity in mind. It should also be able to be easily adjustable for tuning purposes. Repair The suspension system will have replacement parts, for some reason our cars suspension is broken. The part can be changed and the car will resume test. But during competition once the car has gone thru Technical Inspection, the only thing that can be changed for the suspension is the springs, sway bars and shims, along will tire pressure. Retirement Upon completion of the Formula SAE competition, the use of the suspension design will be up to the discretion of the following years team executive board as well as the lead of the suspension design. The completed race car will be returned to the SAE Shop and kept for future design reference and improvements. Company Requirements Marketing Our product will be marketed, tested and demonstrated a prototype vehicle for the non-professional, weekend drivers, and the competition market. Manufacturing All of our parts well either be bought from manufactures that either specialize in the components that we are need to buy. For example (Miller Bearing, Aurora

bearing). While that stock will be machine in your shop on our CNC mill or lathes, with stock bought from Alro Steel, or other companies for the cheapest material. Financial Our finance will come from 3 places. They are as followed, UCF SAE Formula Team, MMAE, SGA, or out of pocket if funds are depleted or low. Regulations/Standards/Codes The suspension system must adhere to the Formula SAE Rulebook, and be designed bearing in mind that the rest of the car must also comply with the rulebook. Patents / intellectual property Most suspension designs are conceptually similar. The design for this suspension would not reflect any breakthrough technology or any experimental components. For this reason, intellectual property would be reflected by the teams numerical data pertaining to the SAE event. In the case that a new method, design or process was discovered serendipitously, the proper methods would be taken in order to secure the intellectual property. Other Appendices Site Visit Data Sales/Marketing Data House of Quality